Sound-record and other object.



I. w. AYLsvI/oRTH 1 E. L. AIKEN SOUND RECORD AND OTHER OBJECT.

APPLICATION FILI-:D SEPT. I0. I9I4.

entran Lerares ramena@ onnronI JONAS W. YLSWORTH, OlE EAST ORANGE,

NEW JERSEY, ANDEDWARD Ll Aimar, on

SPRINGFIELE, MASSACHUSETTS, ASSIGNORS, BY MESNE ASSIGNMENTS, TO THOMAS A. EDISON, INCORPORATED, OF WEST ORANGE, NEW JERSEY, A CORPORATION OF NEW innerer.

insista.

SOUND-RECORD AND OTHER OBJECT.

Grignal application led'August 6, 1910, Serial No. 575,981. Divided and this application led September 10, 1914. Serial No. 861,038.

To all whom it may concern Be it known that we, JONAS W. Arnswon'ru, a citizen of the United States,v and a'. resident of East Orange, Essex county, New

Jersey, and EDWARD L. Arnim, a citizen of the United States, and a resident ofSpringfield, Hampden county, Massachusetts, have invented certain new and useful llmprovements in Sound-Records and other Objects, of which the following is a' description.

Our invention relates to molded objects, especially dat plates, such 'as disk sound records, and more particularly to the disk sound record and other molded objects y'formed by our improved process described and claimed in our application, Serial No. 575,981, filed August 6, 1910, of which this application' is a division. By our improved p rocess, molded objects are formed of resinoiis refractory condensation products of phenol or equivalent substances, and formaldehyde or other materia-l containing active methylene (CH2) groups.

Our principal object is toproduce as an article of manufacture various moldedobjects such as disk sound records, formed by our improved-process, and having certain distinguishing characteristics which will hereafter be more fully pointed out.

. @ur process consists generally in the formation of a body or backing having a large proportion of an inert filling material incorporated therein, the formation of a surfacing layer, having a less proportion of filler or no filler, securing or forming the surfacing layer upon the body, and molding the object from the blank thus formed, while at the same time causing the reaction to ensue between the ingredients of the object vor of the surface vlayer thereof by applicaytion of sufficient heat to form a'final infusible and insoluble condensation product.

` ln carrying out our process, we prefer 'to proceed as follows A fusible soluble phenolic condensation product or phenol resin lis formed. This` is preferably the product formed the reaction of substantially three parts of phenol to two parts of formaldehyde by molecular weights, the. reaction apparently taking place according to the equation- 65H50 CH2 3(C,u,oH)+2(cH2o)= c6H4o ,\`on,oV

as explained inrapplications of Aylsworth, Serial No. l9t,060, iled May 14, 1909, entitled Plastic composition and process of manufacturing the same, and Serial No. 543,238, filed February 11, 1910, entitled Phenolic condensation product and method of preparing the same, upon which applications ll. S. Patents N os. 1,102,630 and 1,020,593 respectively have been granted. l/Vhether or not the reaction takes place according to theequationgiven, the resulting condensation product is fusible and soluble in alcohol and other solvents and is av solid at normal temperatures Apparently, this product contains no free formaldehyde or other free or active methylene-containing substance, and it is permanently fusible in the sense that it cannot be transformed into an infusible final condensation product by any amount of heating with or without pressure without the addition of formaldehyde, paraformaldehyde, licita-methylene- .tetra-amin, or other hardening agent, but upon being heated togetherwith a sufficient quantity, as 10%, of such hardening agent, a transformation takes place changing the phenol resin into a inal infusible insoluble condensation product, as is explained in the applications of Aylsworth above referred to.

ratenteaaag. si, rais...

To make the blank or body of a disk sound l We prefer to vthe proportion of about 10 per cent. of the phenol resin, and this is preferablyrst disl the alcohol, since the hexa-methylene-tetra- 1 mixture.

' the mold` to form the blank.

f. preferably amin dissolves more readily in water than in alcohol. Next, an inert filling body such as dry wood pulp 0r other filling materials, such as are described in the applications of Aylsworth above referred to, are placed in a mixing machine, and if desired, a coloring material, such as lamp black, is added to the The solution vof the phenol resin and the hardening agent is then poured into the mixing machine upon the filler and the componentsv are thoroughly mixed together. The solvent is-then removed as by evaporation, the 'alcohol preferably being recovered,

and used over and over. rlfhe dried mixture resulting is then ground to uniformity and molded preferably in a hydraulic press with a suitable amount of heat, preferably about 300 degrees F., steam heat, the blank or body thus being formed. 1n this molding operation, the hardening reaction between the phenol resin and the hex'a-methylenetetra-amin may take place to a limited extent, although it is only necessary that the materials be sufficiently heated to coalesce in The filling body may be used with good results. in the proportion of two or three to one by weight to the phenol resin. The pro ortions of the filler to the binder in the al hardened product, vthough slightly less than the proportions given, same.

rfhe Ysurfacelayer for the object to be molded is preferably formed as follows z-A sufficient amount of phenol resin, together with a hardening material, preferably hexamethylene-tetraeamin, a plasticity agent, such as described in the applications of Aylsworth above referred to, and which is chlorinated naphthalene, as mOndChlOrO-naphthalene, gether, with a percentage of an inert filler less than the percentage used in the case of y the mixture for the blank above described.

' chlorinated naphthalene,

Preferably, a percentage" of the blank mixture itself is used for incorporation with the vother ingredients' to provide the filling body.

We have obtained good results with the following propor-tionsz--phenol resin 100 parts; blank mixture 10 to 40 parts; monochloro-naphthalene 15 to 30 parts; hexamethylene-tetra-amin 10 to 12 parts. Preferably, the hexa-methylene-tetra-amin 1n perfectly dry condition is first ground through a paint mill together with the which is rendered liquid if necessary by heat. This operation results in the formation of a paste. The phenol resin is then ground and the desired amount of the blank mixture stirred into the together with the will, be approximately the are ground tosufficient to cause tlie formation of the sheet,

but not to cause the reaction between the ingredients. rlhe surface layer in the form of sheets is then fixed to the blank in any. suitable manner. molded, such as adisk sound, record, the heated blank together with a surfacing sheet is passed between warm rolls. 1n the case of a disk sound record which'it is desired to mold upon both sides, a surface layer is secured to each side of the blank by passing the heated blank with the surfacing sheets on both sides of the same through the rolls, |The plasticity agent referred to renders the surface sufficiently plastic at elevated temblank is now ready to be molded and is placed in a suitable mold, heated sufficiently, and pressed preferably in a hydraulic press, the reaction ensuing between the ingredients of the composition while in the press to harden the 1giolded object into a final in.- fusible and insoluble product, the body and the surface layer being one homogeneous mass. Upon cooling, the finished molded object may be removed from the mold.

We prefer to use hexa-methylene-tetraamin as a hardening agent for reasons given in 'applications of ylsworth, 'Serial No. 543,236 and 543,238, upon which U. S; Patents Nos. 1,146,388 and 1,020,593 respectively hyde or other stances may be used.

1n the case of a plate to be` tion, there is no evolution of dissociation gases, ingly, need not be used to prevent gassing in the composition, pressure being used only for the purpose of giving the object the desired form. lathe case of various objects, it will not be necessary to perform the entire reaction within the mold during the densation product ground fine and mixedv with the other ingredients,inplace of wood pulp or other organic or inorganic fillers. This is mentioned in. applications of Aylsand counteracting pressure, accord! and Serial No. 57 5,970, filed August 6, 1911,

worth, Serial No. 543,236, above referred to,

upon which last named application U. S. Patent No. 1,102,631 has been granted.

In the drawing forming part of this specification is shown a side elevation of one embodiment of my invention, the materials employed in the said embodiment being described on the drawing.

lt is obvious that our invention is not liml ited to the particular details described, but that the latter may be modified within the scope of the appended claims without departing from the spirit of the invention.

The body of the record or other object n formed should upon molding make a homogeneous mass with the surface layer, to obtain the best results, but for some purposes the body`,may be formed of an inert ller and a binder other than a phenolic condensation product, particularly if the body is of material having substantially the same coefficient of expansion as the surface layer which `in such case is in the nature of a veneer applied to the backing.

Having now described our invention, what we claim and desire to protect by Letters Patent lisy as follows:

1. As a new article of manufacture, a

sound record or vblank comprising a body of suitable material and a surface layer containing a final hardened phenolic condensation product having incorporated therewith va substance which renders the surface layer sufficientlyv plastic at elevated temperatures to be pressed or molded', substantially as described.

- 2. As av new article of lmanufacture, a' p sound record or blank comprising a body containing a filler and a binding agent and a surface layer containing a final hardened phenolic condensation product having incprporated therewith a substance which renders the surface' layer `sufciently plastic at elevated temperatures to be pressed orrmolded,

substantially as described. f

3. As aynew article of manufacture, a sound'record or blank comprisingI a body-of suitable material and a surface layer containing a final hardened condensation .product formed from a permanently fusible p'he-.

' nol resin'and a material containing an active methylene group, ysubstantially as described.

4. As a new article of manufacture, Va sound record or blank comprising a body of suitablematerial and a surface layer containing a final hardened condensation product formed of a phenol resin and a material containing an active methylene group, said product hav-ing a plasticity agent incorporated therewith, substantially as described.

5.' As a new articfe of manufacture, a sound record or blank comprising a body containing a filler and a phenolic binding sound record or blankcomprising a body containing a final hardened condensation product formed of a phenol and a substance containing an active methylene group, and a surface layer containing a final hardened phenolic condensation product having a plasticity agent incorporated therewith, substantially as described.

8. As a new article of manufacture, a sound record or blank comprisingva body containing4 a filler and a binder formed of a condensation product of a phenol and a substance containing an active methylene group, 'anda' surface layer containing a final hardened phenolic condensationproduct having a' plasticity agentincorporated therewith, substantially c as described.

9. As a newarticle of manufacture, a sound record or blank comprising a body -containing a ller and a'binder formed of a --flnal` hardened condensation product of a phenol anda substance containing an active methylene group, and a surface llayer containing a yfinal hardened phenolic condensaorated therewith, substantially as described. l0.` A fiat sound record'` or other` object havingv a body of suitable material andra surface layer containing ahardened phenolic condensation product on both sides or faces of said body, said product having incorporated therewith a substance which renders the surface layer sufficiently plasticV at elevated temperatures to take a clear impression from a sound record matrix, substantially as described.

record or other object l1. A flat sound v tion product having a plasticity agent incori having a body containing a iller and a biding agent therefor and ansurface la er containing a hardened phenolic condensation ,product on both sides or faces of said body, said product having incorporated therewith a substance which rendersthe surface layer sufficiently plastic at elevated temperatures to take a clear impression fromy a sound record matrix, substantially as described.

12.. A` flat sound record or other object having a body containing a phenolic ller and a binding agent therefor and a surface layer containing a hardened phenolic con densation product o n both sides or facesof .A

said body, said product having incorporated therewith a substance. which renders the surface layer suiiicieiitly plastic at elevated temperatures to take a clear impressionfrom a sound record matrix, substantially as de! scribed.

A13. A flat sound record o'r other object having a body containingahardened phenolic condensation product and a filler and a surface layer containing a hardened phenolic condensation product on both .sides or faces'of said body, said product-,having incorporated therewith a substance which renders the surface ,layer suiiiciently plastic,

- at elevated temperatures to takel a clear im-V pression from afsound record matrix, substantially as described. s

14. As a new article,v of manufacture, a 1 sound record or blankfcomprising a body trix, substantially as described.r

15. As a new article ofmanufacture, a

sound record or blank comprising a body containing a filler of wood fiber and a binder therefor `containing a phenolic condensation product, the wood fiber being in-excess of the binder, ,and a surface layer containing a hardened phenolic condensation product,

' said surface layer being suiiciehtly thermo tially as described.

plastic to 'take when heatedaclear impression from a sound` record matrix, substan- 16. lAs a new article of manufacture, a

` sound record 'for ,b`lank comprising a' ,body

containing a filler of wood fiber and a binder therefor containing a hardened phenolic ycondensation product, the wood fiber being in excess of the binder,`an d a surface layer containing a hardened phenolic condensation product, said surface layer being suiiy ciently thermo plastic totake when heated a clear impression from a sound record matrix, substantially as described.

17. As a new article ofv manufacture, a

sound [record or blank comprising a, body containing a fillenof'wood ber and a`binding agent and a surface layer containing a final hardened phenolic condensation'prody uct having incorporated therewith a substance which renders the surface layer suiiciently plastic at elevated temperatures to lbe pressedor molded, substantially as de,-

scribed.

18. As a new article sound record or blank comprising a body containing a filler of wood fiber 'and a resinous binding agent land a surface layer containingy a final hardened phenolic condensation product having incorporated therewith a substance which renders the ,d surface layer sufficiently plastic at elevated temperatures to be pressed or molded, substantially as described.

19. As a new article of manufacture, aA -sound record o'r blank comprising a body containing afillerl and a binding agent, the filler being in excess of the binding agent, and a surface 'layer containing a final hardened phenolic condensation; product having a plasticity agent incorporated therewith,

substantially as described.

20. As a new article of manufacture, a

sound record or blank comprising a body containing a filler of wood and a bindingagent, the filler being in excess of the binding agent, and a surface layer containing a lfinal hardened phenolic condensation product having a plasticity agentincorporated therewith, substantially as described.

This specication signed by me, the said JONAS W. AYLsWoRTH, and witnessed on my behalf the 2nd day of September, 1914, and

signed by me, the said EnWARD L'. AIKEN,

of manufacture, a

and witnessed on my behalf the 3rd day of September, 1914,.

- JNAS W. AYLSWORTH.

Witnesses:

FREDERICK BAGHMANN,

MARY J. LAIDLAW.

EDWARD L.

- AIKEN. Witnesses:

E. GEO. MosELEr,

GEORGIANNA DROLETTE. 

